Making The Eccentric - Valve Connecting Rod

The connecting rod was made from some scrap sheet of the right thickness as I did not have the correct MS flat to the Stuart specification i.e. 1/4" x 3/32" (6.35 x 2.4mm).  I cut a longer piece than necessary to allow for final fitting.  To cut it I used my favourite 'file handle' grip hacksaw.  It is an ugly but ancient tool, rather like myself some would say, but I have a soft spot for it as it belonged originally to my grandfather, and he died in the late 1950s aged 72, so it has earned it's keep over the years.

Initial Cutting of Connecting Rod Blank

 As I was cutting obviously I reached the limit of the effective sawing which was restricted by the length of the hacksaw frame (I am using a coarse 18tpi 10" (250mm) blade.  I can get away with a coarse blade as I am cutting at a low angle, it is important for accurate work and to prevent blade breaking that there are always at least three teeth in contact with the work at all times.  In order to overcome the problem the blade is turned through 90º and now I can carry on cutting for as long as I like.

Blade Turned Through 90º

Here is the strip blank cut together with the HI Tech tools I used.  The cutting took me around 4 minutes in total.  The age of the Hacksaw really shows but it is capable of quite accurate work. By the way, these tools except for the stainless rule, were salvaged from the fire and refurbished,  I fitted a new (old) handle to the hacksaw.

Tools Used To Cut Blank

 

'Nose' of Toolmakers Clamp seen at Upper Left.

 Next I draw filed the flat sides of the blank as I was going to mill it to near width later.  The picture below shows the blank supported on a 12 mm square bar in my small bench vice.  The end was clamped with a traditional toolmakers clamp, a very effective tool if used correctly, unfortunately many users don't bother to set the jaws near parallel before using.  Tremendous clamping force can be applied.

I used a number of files of increasingly fine teeth finishing with emery cloth supported by a 10" flat file.  I had to be careful to keep the face flat and was reasonably successful.

Milling, Using a Ground Bar to Aid Vice

I then milled the edge roughly to size.  The blank was supported on narrow parallels but they were too thick for the vice to clamp so I used an accurate ground bar (from an old, broken printer -  what would we do without Mr HP's scrap?) to act as a spacing clamp bar.

The blank was too long for the vice so I had to mill half and then move it along for the second half to be machined.  Not precision but I was going to file the edge eventually so I wasn't too worried.

After finishing one edge I filed it straight by hand - it was only a few thou' out anyway - and polished the first edge  I then milled the second edge.

Draw Filing Blank in Small Bench V

The final job was to file the blank to 1/4" width (6.35mm or 0.250").  As before this was done with  succession of files, getting finer as I went along.  It was then finished with emery as before I went from 150 emery down the grades to 600 grade. which gave a reasonable finish to the part.

I was pleased with the final blank as it was to within half a thou' (0.0005") over it's length - see pictures below.  This sort of accuracy is not necessary on such a component, after all it could be shaped like a Chines Dragon for all that matters, but I like to get a job right if I can without too much hassle.

Once it was to size It was a simple task to transfer the holes from the strap.  I did that by glueing the parts together with Loctite and using the holes in the strap as a drill guide.  I would normally use a clamp but this component is too small.

Images showing the width of the connecting rod at both ends and the centre, which is 0.005" narrower.  I don't think that I'll worry about that!

Width at 'Top' End

Width at Middle.

Width at 'Bottom' end.

A result! 

It took around 30 minutes to get here but much of that time was taken up by getting a good finish on the blank, and drilling etc. which I would have had to have done on MS flat a real plus was that I didn't have to pay excessive postal costs and wait three or four days for it's arrival.  By recycling old material I was able to carry on the work in hand quickly, saved myself money, had the satisfying warmth of a job well done plus I did a bit for the environment.  The photographic time was extra.

Valve Gear For the Stuart Beam Engine

Eccentric and Strap - Part 1 Strap

 

My Drawing of The Eccentric Strap - To Scale

The First part I decided to make for the Stuart Beam was the eccentric sheave, strap and connecting rod.  The strap was the first to be made as the eccentric sheave is made to fit.  In the original kit the strap is made from a casting, but the original was lost and Stuart Models had been sold to new owners at the time, so I decided to fabricate one from solid. Firstly I drew up the strap accurately to scale from the Stuart drawings.  I then used this as a rough cutting template by sticking it to the brass blank with the simple use of PVA white glue.  This holds very well but is eventually easy to remove.

Unfortunately I had no 1/4" thick brass stock but I have some 1/8" flat, so I silver soldered two pieces together using high silver low temperature solder.to make up the thickness.  I did this by flattening a length of round silver solder and made it into a ring around the same diameter as the strap.  The parts were fluxed, the silver solder positioned and the 'sandwich' was made.  In order to prevent the parts moving too much when soldering I arranged that the 'sandwich' was restrained on two sides by firebrick.  The parts were heated and successfully soldered.  I had tried to soft solder the parts but that was not as successful as the use of Silver Solder.  Soft soldering, if properly carried out, is much stronger than most folk realise.  It does no just act as a 'glue' sitting between two surfaces.  A perfect soft soldered joint will have the thinnest possible layer of actual solder as it should actually alloy with the parent metals it is joining at the boundaries of the joint.  It is strong in tension and shear (obviously in compression as well).  However it is weak in 'peel'. therefore those situations should be avoided.

Back to Making

The first stage was to cut the blank across where the joint is to be made. The edges of the two halves were milled accurately.  They were then drilled tapping size.  The hole in the cap were opened out to 7BA clearance while the hole in the body were tapped 7BA. The two parts were bolted together ready to bore out to size.  You should be able to see what I mean in the picture below.

 The blank was then mounted in the 4 Jaw independent chuck and the part centred where the eccentric sheave is to be located.  I drilled out as much as I could, step drilling up to my largest drill. 











The boring bar was then used to bore the strap to size.  It has a groove to locate the sheave so a HSS tool was ground up for the boring bar and the groove carefully bored. 

One point to note is that I ensured that the blank was located in the chuck accurately by using a steel block held against the front of the jaws with the tailstock, and the blank, just held gently in the jaws of the chuck was forced against the block before tightening the jaws of the chuck hence locating it accurately.

After boring the strap was finished by milling and filing to shape using normal practices.  The initial profile was rough milled and then the part was filed to profile with a succession of finer files and abrasives.  It is shown here with it's eccentric before the eccentric and boss were drilled and turned.

It is now just in need of a bit of final bling to get to a high finish.  however I do not want it to be too perfect as I prefer the model to reflect an engine in 'working condition', I'm not to keen on those Highly polished ones I see on the exhibition circuit and in magazines from time to time.

Stuart Beam engine - see text for source.

Hi, I'm back again after a long break.  I have managed to get a reasonable workshop up and running and I will post a few articles and photographs of developments in a little while.  The main picture here is not of my engine but a lovely example of the same Stuart Beam, which I 'borrowed' from IndianaRog and the Temple of Steam - here.  If he wishes me to remove it, please contact me and I will comply.

I have now started a few projects, I tend to keep two or three on the boil as it helps to keep my short attention span concentrated.  Also I lost my lifetimes collection of tools, equipment and materials in the fire which destroyed my garage/workshop.  Hence, when I realise I haven't replaced something, I often have to postpone work until I can order replacement tools and /or materials.  Also I have been making a few workshop aids and tools as I go along as need demands.

At present I am  concerned with refurbishing a Stuart Beam Engine and Boiler.  These were obtained from a friend some years ago and a second friend offered to refurbish the poorly made model.  Unfortunately that 'friend' was not very reliable and left the model in component form after stripping it down to the last nut and bolt.  I took the model back and stored it for a while but it was in the garage fire.  I managed to salvage the main parts i.e. the column and beam, the main base and flywheel plus crankshaft as well as the cylinder.  Most of the other parts were wither lost in the fire, too badly damaged to repair or simply badly made.  The boiler was badly damaged but I have put that aside while I concentrate on the main engine itself.

Workshop and Facilities

Garage/Workshop Fire, Before Fire Fighters Arrived

I had the unfortunate experience of having my large detached garage being burnt down. Probably caused by an electrical fault according to the chief duty fire officer. We were tended by three fire appliances at one time and created chaos by closing a busy main road for around one and a half hours.

I lost just about all of my tool collections which went back to my early apprenticeship days, about 50 years now. I also lost my models and tools that I had made or was in the process of building with the exception of a small vertical boiler oscillating steam engine built for a grandson. On top of this I lost all of my machinery including a benchtop milling machine, lathes, grinders, compressors and a host of woodworking equipment.

The upside now is that I have a chance to plan my workshop from scratch and equip it with compatible machinery which I had not done before, so the first part of the blog will be concerned with building and equipping my garage/workshop which may help some others starting out which is effectively what I am doing myself.

Beginning

Welcome, I intend to report hints and tips about model engineering and modelling as I experience and discover the world of model engineering. It will include all sorts of stuff I hope including diary of building specific models and any problems I find. The good, the bad, and the ugly will all appear. Mistakes as well as triumphs perhaps to help others not to repeat the mistakes and enjoy more triumphs.